Complete service repair manual with Electrical Wiring Diagrams for Komatsu Dump Truck HD465-7E0, HD605-7E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Dump Truck HD465-7E0, HD605-7E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN01081-18 – Dump Truck HD465-7E0, HD605-7E0 Shop Manual.pdf
GEN00046-04 – Dump Truck HD465-7E0, HD605-7E0 Field Assembly Instruction.pdf
TEN00138-08 – Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual.pdf
TEN00332-00 – Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual.pdf
TEN00370-03 – Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual.pdf
TEN00439-07 – Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,390 pages
File Format: PDF
Language: English
MAIN SECTIONS
GEN00046-04 – Dump Truck HD465-7E0, HD605-7E0 Field Assembly Instruction…2
COVER…2
CONTENTS…3
1. Major points changed from model 7…5
2. Outline of division…5
3. Dimensions of main components…6
4. Rough schedule of assembly and welding4. Rough schedule of assembly and welding…7
5. List of equipments, tools, and consumables…10
6. Assembly process No…12
List of jigs, tools, and consumables…12
0010 Oil, grease, and coolant…13
0020 Levels of oil, grease, and coolant…14
0030 Positioning rear axle assembly…15
0040 Installing rear suspension…16
0050 Installing of axle rod (upper)…17
0060 Slinging bare machine…18
0070 Installing rear axle assembly (Connecting axle rods)…19
0080 Connecting rear suspension…20
0090 Positioning bare machine…21
0100 Installing right front axle (Connecting A-arm)…22
0110 Installing right front axle (Connecting suspension)…23
0120 Installing right front axle (Connecting steering cylinder and tie rod)…24
0130 Installing right front axle (Connecting brake hose)…25
0140 Installing right front axle (Connecting piping for automatic suspension)…26
0145 Connection and fixing of right front axle wiring harness (ABS specification)…28
0150 Installing tire and wheel assembly…29
0160 Installing body hinge grease tube…30
0165 Installation of rear monitor…31
0170 Installing drive shaft…32
0180 Connecting cooling hose…33
0190 Connecting brake actuating hose…34
0195 Connection and fixing of rear centralized lubrication hoses [4-point greasing…35
0200 Installing right front support…36
0210 Installing R.H platform assembly…37
0215 Fixing of ORBCOMM antenna cable…38
0216 Installation of ORBCOMM antennal pole…39
0220 Installing of fire prevention cover…40
0221 Installation of fire prevention cover (Sand terrain specification)…41
0230 Installing right fender…42
0231 Installation of right fender (Side lamp specification)…43
0240 Installing L.H catwalk assembly…44
0250 Installing L.H handrail…45
0251 Installation of cab side step (Diagonal ladder specification)…46
0252 Installation of diagonal ladder 1 (Diagonal ladder specification)…47
0253 Installation of diagonal ladder 2 (Diagonal ladder specification)…48
0254 Installation of diagonal ladder 3 (Diagonal ladder specification)…49
0255 Assembly of diagonal ladder (Diagonal ladder specification)…50
0256 Installation of under view mirror (Diagonal ladder specification)…51
0260 Installing radio antenna and fixing its cable…52
0270 Installing L.H fender…53
0271 Installation of left fender (Side lamp specification)…54
0280 Installing left side mudguard…55
0290 Installing right side mudguard…56
0295 Installation of R.H exhaust pipe cover (Muffler specification)…57
0296 Installation of R.H exhaust pipe cover (Exhaust selector box specification)…58
0300 Installing transmission underguard…59
0305 Installation of radiator curtain (Radiator curtain specification and sand terrain specification)…60
0310 Removing hoist cylinder bracket…61
0320 Removing hoist piping blind plate…62
0330 Welding body…63
0340 Slinging body…64
0350 Installing hinge pin…65
0360 Connecting hoist cylinder…66
0370 Welding protective cover by actually positioning it on machine…67
0380 Installing body mount…68
0390 Procedure for adjusting body mount shim…69
0395 Welding front body mount bracket…70
0400 Welding exhaust tube by actually positioning it on machine…71
0405 Installation of grease junction tube [4-point greasing specification]…72
0410 Installing poke ejector…73
0420 Installing body lock pin…74
0430 Installing body mudguard…75
0440 Connecting dump sensor…76
0450 Procedure for adjusting dump sensor…77
0460 Calibrating dump control…78
0470 Bleeding air from brake system (Preparation)…79
0480 Bleeding air from brake system (Front)…80
0490 Bleeding air from brake system (Rear)…81
0500 Adjusting suspension…82
0510 Greasing (Right front axle)…83
0520 Greasing (Hoist cylinder)…84
0530 Greasing (Rear suspension and axle rod)…85
0540 Painting…86
0550 Sticking body decal…87
0560 Removing jig…88
0570 Adjusting angles of mirrors…89
0580 Checking/Adding lubricants…90
C-0010 Preparation of welding body…91
C-0020 Assembly of split body…92
C-0030 Tack welding body…93
C-0040 Welding body…94
C-0050 Welding body instruction (1/2)…95
C-0060 Welding body instruction (2/2)…96
C-0070 Turn over the body…97
C-0080 Welding body protector (1/2)…98
C-0090 Welding body protector (2/2)…99
C-0100 Finishing and painting welded parts of body…100
C-0110 Reworking on body (Exhaust selector box specification)…101
C-0120 Welding of body exhaust pipe (Exhaust selector box specification)…102
Appendix : Field assembly inspection report…103
SEN01081-18 – Dump Truck HD465-7E0, HD605-7E0 Shop Manual…113
TEN00138-08 – Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual…1759
COVER…1759
FOREWORD…1760
BEFORE READING THIS MANUAL…1761
SAFETY INFORMATION…1764
INTENDED USE…1765
USE OF MACHINE…1765
GENERAL VIEW AND DIRECTIONS OF MACHINE…1765
VISIBILITY FROM OPERATOR'S SEAT…1765
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1766
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…1766
EPA REGULATIONS, ENGINE NUMBER PLATE…1766
SERVICE METER POSITION…1767
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1767
CONTENTS…1768
SAFETY…1772
IMPORTANT SAFETY INFORMATION…1773
SAFETY LABELS…1776
POSITION FOR ATTACHING SAFETY LABELS…1777
SAFETY LABELS…1778
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…1783
PRECAUTIONS BEFORE STARTING OPERATION…1783
PREPARATIONS FOR SAFE OPERATION…1783
FIRE PREVENTION…1785
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…1786
DO NOT GET CAUGHT IN DUMP BODY…1788
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…1788
UNAUTHORIZED MODIFICATION…1788
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…1789
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…1789
PRECAUTIONS FOR OPERATION…1790
PRECAUTIONS FOR JOBSITE…1790
STARTING ENGINE…1792
OPERATION…1794
TRANSPORTATION…1798
TOWING…1799
PRECAUTIONS FOR MAINTENANCE…1800
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…1800
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…1804
TIRES…1809
OPERATION…1812
GENERAL VIEW…1813
GENERAL VIEW OF MACHINE…1813
GENERAL VIEW OF CONTROLS AND GAUGES…1814
DASHBOARD…1815
EXPLANATION OF COMPONENTS…1816
GENERAL VIEW OF MACHINE…1816
OPERATOR'S CAB…1819
CONTROL LEVERS AND PEDALS…1821
MACHINE MONITOR…1826
DISPLAY OF CHARACTER DISPLAY…1839
OTHER FUNCTIONS OF CHARACTER DISPLAY…1843
SWITCHES…1847
BODY PIVOT PIN…1857
LOCATION OF FIRE EXTINGUISHER…1858
DUST INDICATOR…1858
FUSES…1859
CAR RADIO…1862
CAR STEREO…1864
AIR CONDITIONER…1869
OPERATION…1874
CHECK BEFORE STARTING ENGINE…1874
STARTING ENGINE…1899
OPERATIONS, CHECKS AFTER STARTING ENGINE…1902
STOPPING ENGINE…1902
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…1903
SHIFTING GEAR…1909
TRAVELING DOWNHILL…1911
STEERING THE MACHINE…1924
LOADING OPERATIONS…1924
DUMP OPERATIONS…1925
PRECAUTIONS FOR OPERATION…1927
PARKING MACHINE…1928
CHECKS AFTER COMPLETION OF WORK…1928
CHECKS AFTER STOPPING ENGINE…1929
LOCKING…1929
HANDLING TIRES…1930
DETERMINING AND MAINTAINING TRAVEL ROAD…1934
DETERMINING TRAVEL ROAD…1934
MAINTAINING TRAVEL ROAD…1934
WORKSITE…1935
EXAMINATION AN CONFIRMATION OF WORKSITE…1935
WORKING ON LOOSE GROUND…1935
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE…1936
ENSURE GOOD VISIBILITY…1936
CONFIRMATION OF MARK…1936
TRANSPORTATION…1937
PRECAUTIONS WHEN TRANSPORTING…1937
STEPS FOR TRANSPORTATION…1937
METHOD OF SECURING MACHINE…1938
METHOD OF LIFTING MACHINE…1939
COLD WEATHER OPERATION…1942
PRECAUTIONS FOR LOW TEMPERATURE…1942
PRECAUTIONS AFTER COMPLETION OF WORK…1944
AFTER COLD WEATHER…1944
LONG-TERM STORAGE…1945
BEFORE STORAGE…1945
DURING STORAGE…1945
AFTER STORAGE…1945
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…1945
TROUBLESHOOTING…1946
AFTER RUNNING OUT OF FUEL…1946
IF TRANSMISSION HAS TROUBLE…1946
METHOD OF LOWERING DUMP BODY IN EMERGENCY…1947
METHOD OF TOWING MACHINE…1949
IF BATTERY IS DISCHARGED…1953
ACTION IF FIRE OCCURS…1957
OTHER TROUBLE…1958
MAINTENANCE…1964
GUIDES TO MAINTENANCE…1965
SECONDARY MATERIALS FOR OPERATION…1972
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1972
OUTLINE OF ELECTRIC SYSTEM…1976
WEAR PARTS…1977
WEAR PARTS LIST…1977
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1978
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1979
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1980
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1981
TORQUE LIST…1981
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1982
SAFETY CRITICAL PARTS…1982
MAINTENANCE SCHEDULE CHART…1983
MAINTENANCE SCHEDULE CHART…1983
SERVICE PROCEDURE…1985
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…1985
WHEN REQUIRED…1986
CHECK BEFORE STARTING…2011
EVERY 250 HOURS SERVICE…2012
EVERY 500 HOURS SERVICE…2026
EVERY 1000 HOURS SERVICE…2036
EVERY 2000 HOURS SERVICE…2046
EVERY 4000 HOURS SERVICE…2049
EVERY 8000 HOURS SERVICE…2053
EVERY 15000 HOURS SERVICE…2054
SPECIFICATIONS…2056
SPECIFICATIONS…2057
ATTACHMENTS, OPTIONS…2058
SELECTING DUMP BODY…2059
HANDLING TACHOGRAPH (TCO20-90W)…2060
EXPLANATION OF COMPONENTS…2060
METHOD OF USE…2063
HANDLING AIR SUSPENSION SEAT…2067
OPERATOR'S SEAT ADJUSTMENT…2067
REMOVAL AND INSTALLATION OF HEADREST…2071
HANDLING AUTOMATIC SPIN REGULATOR (ASR)…2072
EXPLANATION OF COMPONENTS…2072
ACTUATION OF ASR SYSTEM…2073
PRECAUTION WHEN USING ASR SYSTEM…2073
TROUBLESHOOTING…2074
BLEEDING AIR FROM ASR CIRCUIT…2075
HANDLING ANTI SKID BRAKE SYSTEM (ABS)…2076
EXPLANATION OF COMPONENTS…2076
ABS SYSTEM CHECK AFTER STARTING ENGINE…2077
OPERATION OF ABS…2078
PRECAUTION WHEN USING ABS SYSTEM…2078
TROUBLESHOOTING…2079
HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)…2080
OUTLINE OF SYSTEM…2080
NORMAL OPERATION DISPLAY…2081
EXTERNAL DISPLAY LAMPS…2083
PERFORMING CALIBRATION…2084
DATA STORED IN PAYLOAD METER…2086
PROCEDURE WHEN DOWNLOADING…2087
MACHINE ID, OPEN ID…2091
PAYLOAD (CYCLE DATA ITEM)…2093
SERVICE FUNCTIONS…2093
OTHERS…2093
HANDLING PAYLOAD METER II (CARD TYPE)…2094
METHOD OF USING ACCURATELY…2095
GENERAL LOCATIONS…2096
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)…2101
EXTERNAL DISPLAY LAMPS…2105
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER…2107
OPERATION OF SWITCHES…2112
PROBLEM AND WARNING DISPLAY (ERROR CODE)…2134
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)…2141
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED…2144
USE OF REAR VIEW MONITOR…2147
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…2147
SETTING OF REAR VIEW MONITOR…2150
CAUTIONS WHEN USING REAR VIEW MONITOR…2150
HANDLING DUMPING COUNTER…2151
HANDLING BATTERY ISOLATOR…2152
HANDLING MACHINES EQUIPPED WITH VHMS…2154
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…2154
VHMS AND COMMUNICATIONS TERMINAL INSTALLED…2154
PROCEDURE WHEN DOWNLOADING…2155
CHECK BEFORE STARTING…2155
INDEX…2158
TEN00332-00 – Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual…2162
COVER…2162
FOREWORD…2163
BEFORE READING THIS MANUAL…2164
SAFETY INFORMATION…2165
INTENDED USE…2166
USE OF MACHINE…2166
GENERAL VIEW AND DIRECTIONS OF MACHINE…2166
VISIBILITY FROM OPERATOR'S SEAT…2166
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2167
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…2167
EPA REGULATIONS, ENGINE NUMBER PLATE…2167
SERVICE METER POSITION…2168
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2168
CONTENTS…2169
SAFETY…2173
IMPORTANT SAFETY INFORMATION…2174
SAFETY LABELS…2177
POSITION FOR ATTACHING SAFETY LABELS…2178
SAFETY LABELS…2179
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…2184
PRECAUTIONS BEFORE STARTING OPERATION…2184
PREPARATIONS FOR SAFE OPERATION…2184
FIRE PREVENTION…2186
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…2187
DO NOT GET CAUGHT IN DUMP BODY…2189
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…2189
UNAUTHORIZED MODIFICATION…2189
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…2190
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…2190
PRECAUTIONS FOR OPERATION…2191
PRECAUTIONS FOR JOBSITE…2191
STARTING ENGINE…2193
OPERATION…2195
TRANSPORTATION…2199
TOWING…2200
PRECAUTIONS FOR MAINTENANCE…2201
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…2201
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…2205
TIRES…2210
OPERATION…2213
GENERAL VIEW…2214
GENERAL VIEW OF MACHINE…2214
GENERAL VIEW OF CONTROLS AND GAUGES…2215
DASHBOARD…2216
EXPLANATION OF COMPONENTS…2217
GENERAL VIEW OF MACHINE…2217
OPERATOR'S CAB…2220
CONTROL LEVERS AND PEDALS…2222
MACHINE MONITOR…2227
DISPLAY OF CHARACTER DISPLAY…2240
OTHER FUNCTIONS OF CHARACTER DISPLAY…2244
SWITCHES…2248
BODY PIVOT PIN…2258
LOCATION OF FIRE EXTINGUISHER…2259
DUST INDICATOR…2259
FUSES…2260
CAR RADIO…2263
CAR STEREO…2265
AIR CONDITIONER…2270
OPERATION…2275
CHECK BEFORE STARTING ENGINE…2275
STARTING ENGINE…2300
OPERATIONS, CHECKS AFTER STARTING ENGINE…2303
STOPPING ENGINE…2303
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…2304
SHIFTING GEAR…2310
TRAVELING DOWNHILL…2312
STEERING THE MACHINE…2325
LOADING OPERATIONS…2325
DUMP OPERATIONS…2326
PRECAUTIONS FOR OPERATION…2328
PARKING MACHINE…2329
CHECKS AFTER COMPLETION OF WORK…2329
CHECKS AFTER STOPPING ENGINE…2330
LOCKING…2330
HANDLING TIRES…2331
DETERMINING AND MAINTAINING TRAVEL ROAD…2335
DETERMINING TRAVEL ROAD…2335
MAINTAINING TRAVEL ROAD…2335
WORKSITE…2336
EXAMINATION AN CONFIRMATION OF WORKSITE…2336
WORKING ON LOOSE GROUND…2336
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE…2337
ENSURE GOOD VISIBILITY…2337
CONFIRMATION OF MARK…2337
TRANSPORTATION…2338
PRECAUTIONS WHEN TRANSPORTING…2338
STEPS FOR TRANSPORTATION…2338
METHOD OF SECURING MACHINE…2339
METHOD OF LIFTING MACHINE…2340
COLD WEATHER OPERATION…2343
PRECAUTIONS FOR LOW TEMPERATURE…2343
PRECAUTIONS AFTER COMPLETION OF WORK…2345
AFTER COLD WEATHER…2345
LONG-TERM STORAGE…2346
BEFORE STORAGE…2346
DURING STORAGE…2346
AFTER STORAGE…2346
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…2346
TROUBLESHOOTING…2347
AFTER RUNNING OUT OF FUEL…2347
IF TRANSMISSION HAS TROUBLE…2347
METHOD OF LOWERING DUMP BODY IN EMERGENCY…2348
METHOD OF TOWING MACHINE…2349
IF BATTERY IS DISCHARGED…2353
ACTION IF FIRE OCCURS…2357
OTHER TROUBLE…2358
MAINTENANCE…2365
GUIDES TO MAINTENANCE…2366
SECONDARY MATERIALS FOR OPERATION…2374
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2374
OUTLINE OF ELECTRIC SYSTEM…2378
WEAR PARTS…2379
WEAR PARTS LIST…2379
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2380
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…2381
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…2382
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…2383
TORQUE LIST…2383
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2384
SAFETY CRITICAL PARTS…2384
MAINTENANCE SCHEDULE CHART…2385
MAINTENANCE SCHEDULE CHART…2385
SERVICE PROCEDURE…2387
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…2387
WHEN REQUIRED…2388
CHECK BEFORE STARTING…2413
EVERY 250 HOURS SERVICE…2414
EVERY 500 HOURS SERVICE…2428
EVERY 1000 HOURS SERVICE…2438
EVERY 2000 HOURS SERVICE…2448
EVERY 4000 HOURS SERVICE…2451
EVERY 8000 HOURS SERVICE…2455
EVERY 15000 HOURS SERVICE…2456
SPECIFICATIONS…2457
SPECIFICATIONS…2458
ATTACHMENTS, OPTIONS…2459
SELECTING DUMP BODY…2460
HANDLING TACHOGRAPH (TCO20-90W)…2461
EXPLANATION OF COMPONENTS…2461
METHOD OF USE…2464
HANDLING AIR SUSPENSION SEAT…2468
OPERATOR'S SEAT ADJUSTMENT…2468
REMOVAL AND INSTALLATION OF HEADREST…2472
HANDLING AUTOMATIC SPIN REGULATOR (ASR)…2473
EXPLANATION OF COMPONENTS…2473
ACTUATION OF ASR SYSTEM…2474
PRECAUTION WHEN USING ASR SYSTEM…2474
TROUBLESHOOTING…2475
BLEEDING AIR FROM ASR CIRCUIT…2476
HANDLING ANTI SKID BRAKE SYSTEM (ABS)…2477
EXPLANATION OF COMPONENTS…2477
ABS SYSTEM CHECK AFTER STARTING ENGINE…2478
OPERATION OF ABS…2479
PRECAUTION WHEN USING ABS SYSTEM…2479
TROUBLESHOOTING…2480
HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)…2481
OUTLINE OF SYSTEM…2481
NORMAL OPERATION DISPLAY…2482
EXTERNAL DISPLAY LAMPS…2484
PERFORMING CALIBRATION…2485
DATA STORED IN PAYLOAD METER…2487
PROCEDURE WHEN DOWNLOADING…2488
MACHINE ID, OPEN ID…2492
PAYLOAD (CYCLE DATA ITEM)…2494
SERVICE FUNCTIONS…2494
OTHERS…2494
HANDLING PAYLOAD METER II (CARD TYPE)…2495
METHOD OF USING ACCURATELY…2496
GENERAL LOCATIONS…2497
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)…2502
EXTERNAL DISPLAY LAMPS…2506
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER…2508
OPERATION OF SWITCHES…2513
PROBLEM AND WARNING DISPLAY (ERROR CODE)…2535
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)…2542
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED…2545
USE OF REAR VIEW MONITOR…2548
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…2548
SETTING OF REAR VIEW MONITOR…2551
CAUTIONS WHEN USING REAR VIEW MONITOR…2551
HANDLING DUMPING COUNTER…2552
HANDLING BATTERY ISOLATOR…2553
HANDLING MACHINES EQUIPPED WITH VHMS…2555
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…2555
VHMS AND COMMUNICATIONS TERMINAL INSTALLED…2555
PROCEDURE WHEN DOWNLOADING…2556
CHECK BEFORE STARTING…2556
INDEX…2559
TEN00370-03 – Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual…2563
COVER…2563
FOREWORD…2564
BEFORE READING THIS MANUAL…2565
SAFETY INFORMATION…2566
INTENDED USE…2567
USE OF MACHINE…2567
GENERAL VIEW AND DIRECTIONS OF MACHINE…2567
VISIBILITY FROM OPERATOR'S SEAT…2567
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2568
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…2568
EPA REGULATIONS, ENGINE NUMBER PLATE…2568
SERVICE METER POSITION…2569
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2569
CONTENTS…2570
SAFETY…2574
IMPORTANT SAFETY INFORMATION…2575
SAFETY LABELS…2578
POSITION FOR ATTACHING SAFETY LABELS…2579
SAFETY LABELS…2580
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…2585
PRECAUTIONS BEFORE STARTING OPERATION…2585
PREPARATIONS FOR SAFE OPERATION…2585
FIRE PREVENTION…2587
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…2588
DO NOT GET CAUGHT IN DUMP BODY…2590
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…2590
UNAUTHORIZED MODIFICATION…2590
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…2591
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…2591
PRECAUTIONS FOR OPERATION…2592
PRECAUTIONS FOR JOBSITE…2592
STARTING ENGINE…2594
OPERATION…2596
TRANSPORTATION…2600
TOWING…2601
PRECAUTIONS FOR MAINTENANCE…2602
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…2602
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…2606
TIRES…2611
OPERATION…2614
GENERAL VIEW…2615
GENERAL VIEW OF MACHINE…2615
GENERAL VIEW OF CONTROLS AND GAUGES…2616
DASHBOARD…2617
EXPLANATION OF COMPONENTS…2618
GENERAL VIEW OF MACHINE…2618
OPERATOR'S CAB…2621
CONTROL LEVERS AND PEDALS…2623
MACHINE MONITOR…2628
DISPLAY OF CHARACTER DISPLAY…2641
OTHER FUNCTIONS OF CHARACTER DISPLAY…2645
SWITCHES…2649
BODY PIVOT PIN…2659
LOCATION OF FIRE EXTINGUISHER…2660
DUST INDICATOR…2660
FUSES…2661
CAR RADIO…2664
CAR STEREO…2666
AIR CONDITIONER…2671
OPERATION…2676
CHECK BEFORE STARTING ENGINE…2676
STARTING ENGINE…2702
OPERATIONS, CHECKS AFTER STARTING ENGINE…2705
STOPPING ENGINE…2706
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…2707
SHIFTING GEAR…2713
TRAVELING DOWNHILL…2715
STEERING THE MACHINE…2728
LOADING OPERATIONS…2728
DUMP OPERATIONS…2729
PRECAUTIONS FOR OPERATION…2731
PARKING MACHINE…2732
CHECKS AFTER COMPLETION OF WORK…2732
CHECKS AFTER STOPPING ENGINE…2733
LOCKING…2733
HANDLING TIRES…2734
DETERMINING AND MAINTAINING TRAVEL ROAD…2738
DETERMINING TRAVEL ROAD…2738
MAINTAINING TRAVEL ROAD…2738
WORKSITE…2739
EXAMINATION AN CONFIRMATION OF WORKSITE…2739
WORKING ON LOOSE GROUND…2739
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE…2740
ENSURE GOOD VISIBILITY…2740
CONFIRMATION OF MARK…2740
TRANSPORTATION…2741
PRECAUTIONS WHEN TRANSPORTING…2741
STEPS FOR TRANSPORTATION…2741
METHOD OF SECURING MACHINE…2742
METHOD OF LIFTING MACHINE…2743
COLD WEATHER OPERATION…2746
PRECAUTIONS FOR LOW TEMPERATURE…2746
PRECAUTIONS AFTER COMPLETION OF WORK…2748
AFTER COLD WEATHER…2748
LONG-TERM STORAGE…2749
BEFORE STORAGE…2749
DURING STORAGE…2749
AFTER STORAGE…2749
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…2749
TROUBLESHOOTING…2750
AFTER RUNNING OUT OF FUEL…2750
IF TRANSMISSION HAS TROUBLE…2750
METHOD OF LOWERING DUMP BODY IN EMERGENCY…2751
METHOD OF TOWING MACHINE…2752
IF BATTERY IS DISCHARGED…2756
ACTION IF FIRE OCCURS…2760
OTHER TROUBLE…2761
MAINTENANCE…2768
GUIDES TO MAINTENANCE…2769
SECONDARY MATERIALS FOR OPERATION…2777
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…2777
OUTLINE OF ELECTRIC SYSTEM…2781
WEAR PARTS…2782
WEAR PARTS LIST…2782
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…2783
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…2784
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…2785
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…2786
TORQUE LIST…2786
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2787
SAFETY CRITICAL PARTS…2787
MAINTENANCE SCHEDULE CHART…2788
MAINTENANCE SCHEDULE CHART…2788
SERVICE PROCEDURE…2790
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…2790
WHEN REQUIRED…2791
CHECK BEFORE STARTING…2816
EVERY 250 HOURS SERVICE…2817
EVERY 500 HOURS SERVICE…2831
EVERY 1000 HOURS SERVICE…2841
EVERY 2000 HOURS SERVICE…2850
EVERY 4000 HOURS SERVICE…2853
EVERY 8000 HOURS SERVICE…2857
EVERY 15000 HOURS SERVICE…2858
SPECIFICATIONS…2860
SPECIFICATIONS…2861
ATTACHMENTS, OPTIONS…2862
SELECTING DUMP BODY…2863
HANDLING TACHOGRAPH (TCO20-90W)…2864
EXPLANATION OF COMPONENTS…2864
METHOD OF USE…2867
HANDLING AIR SUSPENSION SEAT…2871
OPERATOR'S SEAT ADJUSTMENT…2871
REMOVAL AND INSTALLATION OF HEADREST…2875
HANDLING AUTOMATIC SPIN REGULATOR (ASR)…2876
EXPLANATION OF COMPONENTS…2876
ACTUATION OF ASR SYSTEM…2877
PRECAUTION WHEN USING ASR SYSTEM…2877
TROUBLESHOOTING…2878
BLEEDING AIR FROM ASR CIRCUIT…2879
HANDLING ANTI SKID BRAKE SYSTEM (ABS)…2880
EXPLANATION OF COMPONENTS…2880
ABS SYSTEM CHECK AFTER STARTING ENGINE…2881
OPERATION OF ABS…2882
PRECAUTION WHEN USING ABS SYSTEM…2882
TROUBLESHOOTING…2883
HANDLING PAYLOAD METER (VHMS BUILT-IN TYPE)…2884
OUTLINE OF SYSTEM…2884
NORMAL OPERATION DISPLAY…2885
EXTERNAL DISPLAY LAMPS…2887
PERFORMING CALIBRATION…2888
DATA STORED IN PAYLOAD METER…2890
PROCEDURE WHEN DOWNLOADING…2891
MACHINE ID, OPEN ID…2895
PAYLOAD (CYCLE DATA ITEM)…2897
SERVICE FUNCTIONS…2897
OTHERS…2897
HANDLING PAYLOAD METER II (CARD TYPE)…2898
METHOD OF USING ACCURATELY…2899
GENERAL LOCATIONS…2900
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)…2905
EXTERNAL DISPLAY LAMPS…2909
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER…2911
OPERATION OF SWITCHES…2916
PROBLEM AND WARNING DISPLAY (ERROR CODE)…2938
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)…2945
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN …2948
USE OF REAR VIEW MONITOR…2951
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…2951
SETTING OF REAR VIEW MONITOR…2954
CAUTIONS WHEN USING REAR VIEW MONITOR…2954
EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER…2955
SOCKET FOR ENGINE HEATER…2955
CONNECTING EXTERNAL POWER SOURCE…2955
RESTARTING ENGINE…2956
HANDLING EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER…2957
HANDLING DUMPING COUNTER…2963
HANDLING BATTERY ISOLATOR…2964
HANDLING MACHINES EQUIPPED WITH VHMS…2966
VHMS INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…2966
VHMS AND COMMUNICATIONS TERMINAL INSTALLED…2966
PROCEDURE WHEN DOWNLOADING…2967
CHECK BEFORE STARTING…2967
INDEX…2970
TEN00439-07 – Dump Truck HD465-7E0, HD605-7E0 Operation & Maintenance Manual…2974
COVER…2974
FOREWORD…2975
BEFORE READING THIS MANUAL…2976
SAFETY INFORMATION…2977
INTENDED USE…2978
USE OF MACHINE…2978
GENERAL VIEW AND DIRECTIONS OF MACHINE…2978
VISIBILITY FROM OPERATOR'S SEAT…2979
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2980
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…2980
EPA REGULATIONS, ENGINE NUMBER PLATE…2980
SERVICE METER POSITION…2981
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…2981
CONTENTS…2982
SAFETY…2987
IMPORTANT SAFETY INFORMATION…2988
SAFETY LABELS…2991
POSITION FOR ATTACHING SAFETY LABELS…2992
SAFETY LABELS…2993
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…2998
PRECAUTIONS BEFORE STARTING OPERATION…2998
PREPARATIONS FOR SAFE OPERATION…2998
FIRE PREVENTION…3000
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE…3001
DO NOT GET CAUGHT IN DUMP BODY…3003
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES…3003
UNAUTHORIZED MODIFICATION…3003
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS…3004
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…3004
PRECAUTIONS FOR OPERATION…3005
PRECAUTIONS FOR JOBSITE…3005
STARTING ENGINE…3007
OPERATION…3009
TRANSPORTATION…3013
TOWING…3014
PRECAUTIONS FOR MAINTENANCE…3015
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE…3015
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…3019
TIRES…3024
OPERATION…3027
GENERAL VIEW…3028
GENERAL VIEW OF MACHINE…3028
GENERAL VIEW OF CONTROLS AND GAUGES…3029
DASHBOARD…3030
EXPLANATION OF COMPONENTS…3031
GENERAL VIEW OF MACHINE…3031
OPERATOR'S CAB…3034
CONTROL LEVERS AND PEDALS…3036
MACHINE MONITOR…3042
DISPLAY OF CHARACTER DISPLAY…3055
OTHER FUNCTIONS OF CHARACTER DISPLAY…3059
SWITCHES…3063
BODY PIVOT PIN…3073
LOCATION OF FIRE EXTINGUISHER…3074
DUST INDICATOR…3074
FUSES…3075
CAR RADIO…3078
CAR STEREO…3080
AIR CONDITIONER…3085
OPERATION…3090
CHECK BEFORE STARTING ENGINE…3090
STARTING ENGINE…3117
OPERATIONS, CHECKS AFTER STARTING ENGINE…3120
STOPPING ENGINE…3121
MOVING MACHINE OFF (FORWARD, REVERSE), STOPPING…3122
SHIFTING GEAR…3128
TRAVELING DOWNHILL…3130
STEERING THE MACHINE…3143
LOADING OPERATIONS…3143
DUMP OPERATIONS…3144
PRECAUTIONS FOR OPERATION…3146
PARKING MACHINE…3147
CHECKS AFTER COMPLETION OF WORK…3147
CHECKS AFTER STOPPING ENGINE…3148
LOCKING…3148
HANDLING TIRES…3149
DETERMINING AND MAINTAINING TRAVEL ROAD…3153
DETERMINING TRAVEL ROAD…3153
MAINTAINING TRAVEL ROAD…3153
WORKSITE…3154
EXAMINATION AN CONFIRMATION OF WORKSITE…3154
WORKING ON LOOSE GROUND…3154
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLE…3155
ENSURE GOOD VISIBILITY…3155
CONFIRMATION OF MARK…3155
TRANSPORTATION…3156
PRECAUTIONS WHEN TRANSPORTING…3156
STEPS FOR TRANSPORTATION…3156
METHOD OF SECURING MACHINE…3157
METHOD OF LIFTING MACHINE…3158
COLD WEATHER OPERATION…3161
PRECAUTIONS FOR LOW TEMPERATURE…3161
PRECAUTIONS AFTER COMPLETION OF WORK…3163
AFTER COLD WEATHER…3163
LONG-TERM STORAGE…3164
BEFORE STORAGE…3164
DURING STORAGE…3164
AFTER STORAGE…3164
PRECAUTIONS BEFORE TRAVELING AFTER LONG-TERM STORAGE…3164
TROUBLESHOOTING…3165
AFTER RUNNING OUT OF FUEL…3165
IF TRANSMISSION HAS TROUBLE…3165
METHOD OF LOWERING DUMP BODY IN EMERGENCY…3166
METHOD OF TOWING MACHINE…3167
IF BATTERY IS DISCHARGED…3171
ACTION IF FIRE OCCURS…3175
OTHER TROUBLE…3176
MAINTENANCE…3183
GUIDES TO MAINTENANCE…3184
SECONDARY MATERIALS FOR OPERATION…3192
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3192
OUTLINE OF ELECTRIC SYSTEM…3196
WEAR PARTS…3197
WEAR PARTS LIST…3197
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3198
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…3199
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…3200
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…3201
TORQUE LIST…3201
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…3202
SAFETY CRITICAL PARTS…3202
MAINTENANCE SCHEDULE CHART…3203
MAINTENANCE SCHEDULE CHART…3203
SERVICE PROCEDURE…3205
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)…3205
WHEN REQUIRED…3206
CHECK BEFORE STARTING…3231
EVERY 250 HOURS SERVICE…3232
EVERY 500 HOURS SERVICE…3245
EVERY 1000 HOURS SERVICE…3255
EVERY 2000 HOURS SERVICE…3264
EVERY 4000 HOURS SERVICE…3268
EVERY 8000 HOURS SERVICE…3272
EVERY 15000 HOURS SERVICE…3273
SPECIFICATIONS…3275
SPECIFICATIONS…3276
ATTACHMENTS, OPTIONS…3279
SELECTING DUMP BODY…3280
HANDLING TACHOGRAPH (TCO20-90W)…3281
EXPLANATION OF COMPONENTS…3281
METHOD OF USE…3283
HANDLING AIR SUSPENSION SEAT…3287
OPERATOR'S SEAT ADJUSTMENT…3287
REMOVAL AND INSTALLATION OF HEADREST…3291
HANDLING AUTOMATIC SPIN REGULATOR (ASR)…3292
EXPLANATION OF COMPONENTS…3292
ACTUATION OF ASR SYSTEM…3293
PRECAUTION WHEN USING ASR SYSTEM…3293
TROUBLESHOOTING…3294
BLEEDING AIR FROM ASR CIRCUIT…3295
HANDLING ANTI SKID BRAKE SYSTEM (ABS)…3296
EXPLANATION OF COMPONENTS…3296
ABS SYSTEM CHECK AFTER STARTING ENGINE…3297
OPERATION OF ABS…3298
PRECAUTION WHEN USING ABS SYSTEM…3298
TROUBLESHOOTING…3299
HANDLING PAYLOAD METER (KOMTRAX Plus BUILT-IN TYPE)…3300
OUTLINE OF SYSTEM…3300
NORMAL OPERATION DISPLAY…3301
EXTERNAL DISPLAY LAMPS…3303
PERFORMING CALIBRATION…3304
DATA STORED IN PAYLOAD METER…3305
PROCEDURE WHEN DOWNLOADING…3307
MACHINE ID, OPEN ID…3311
PAYLOAD (CYCLE DATA ITEM)…3313
SERVICE FUNCTIONS…3313
OTHERS…3313
HANDLING PAYLOAD METER II (CARD TYPE)…3314
METHOD OF USING ACCURATELY…3315
GENERAL LOCATIONS…3316
CONTENT OF DISPLAY (CONTROLLER, EXTERNAL DISPLAY LAMPS)…3321
EXTERNAL DISPLAY LAMPS…3325
DETAILS OF DATA STORED IN MEMORY OF PAYLOAD METER…3327
OPERATION OF SWITCHES…3332
PROBLEM AND WARNING DISPLAY (ERROR CODE)…3353
WHEN ERROR CODE F-09 IS DISPLAYED (PROCEDURE FOR REPLACING BATTERY)…3360
OPERATION WHEN ERROR CODE F.CAL IS DISPLAYED OR CONTROLLER HAS BEEN REPLACED…3363
USE OF REAR VIEW MONITOR…3366
NAME AND FUNCTON OF EACH PART OF REAR VIEW MONITOR…3366
SETTING OF REAR VIEW MONITOR…3369
CAUTIONS WHEN USING REAR VIEW MONITOR…3369
EXTERNAL POWER SOURCE TYPE ELECTRIC HEATER…3370
SOCKET FOR ENGINE HEATER…3370
CONNECTING EXTERNAL POWER SOURCE…3370
RESTARTING ENGINE…3371
HANDLING DUMPING COUNTER…3378
HANDLING BATTERY ISOLATOR…3379
HANDLING MACHINES EQUIPPED WITH KOMTRAX Plus…3381
KOMTRAX Plus INSTALLED, COMMUNICATIONS TERMINAL NOT INSTALLED…3381
KOMTRAX Plus AND COMMUNICATIONS TERMINAL INSTALLED…3381
PROCEDURE WHEN DOWNLOADING…3382
CHECK BEFORE STARTING…3383
INDEX…3387
Komatsu Dump Truck HD465-7E0, HD605-7E0 Repair Service Manuals